Raw materials. MALT (Malted cereal, usually barley) WATER

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1 Jelena Stojanovic

2 Some history In Babylonia 6000 B. C first recorded document about beer By 4000 B. C there was 16 different types of beer made from barley and honey Imperial Egypt, 4000 B. C had 4 types of beer 2300 B. C China had beer called Kiv Inca Indians made beer from corn Aztec Indians in Mexico made beer from cactus and called it pulque

3 History -Europe Egypt-Greece-Rome-Spain-Germany The old Germanic tribes quickly learned to make beer from germinated barley and called it PEOR or BIOR In Europe, until the 13 th century oats was the most widely used grain for beer making

4 History - America Columbus was given corn beer by the Indians 1548-First colonization attempt in Virginia put small brewery and made beer from corn Thomas Jefferson, Samuel Adams, George Washington were all brewers

5 Raw materials MALT (Malted cereal, usually barley) WATER HOPS ADJUNCT Additional carbohydrate (corn, rice.) YEAST CO 2 can be added in addition to naturally formed one Sugars (glucose, fructose) Enzymes

6 Chemistry Two distinctive processes are present 1. Saccharification and liquefaction break down of starch into simple sugars (glucose), maltose, maltodextrins and oligosaccharides 2. Fermentation- break down of sugars under anaerobic conditions to ethanol and CO 2

7 STARCH AMYLOSE (20-30%) linear polymer of glucose molecules connected with α 1-4 glycosidic linkage AMYLOPECTIN (70-80%) branched polymer of glucose molecules with α 1-4 glucosidic linkage and l 1-6 glycosidic linkage at the branching points

8 Starch Starch is the major carbohydrate reserve in plant tubers and seed endosperm where it is found as granules Each granule typically contains several million amylopectin molecules accompanied by a much larger number of smaller amylose molecules

9 Starch breakdown Acid hydrolysis (not suitable in food industry) to glucose Enzymatic hydrolysis α Amylase β - Amylase Glucoamylase Enzymes are provided by malted barley Use of commercially available enzymes, usually isolated from microorganism is very expensive

10 It is Endoenzyme α Amylase Hydrolyses α 1-4 linkage inside of starch molecule Main product are maltodextrins (few molecules of glucose linked together)

11 β -Amylase Exoenzyme- hydrolyses starch molecule from the end Main product is maltose 92 glucose molecules linked together with α 1-4 linkage)

12 Glucoamylase Can hydrolyze α 1-6 glucosidic linkage (branch points) Responsible for starch debranching Can also hydrolyze α 1-4 glucosidic linkage from the end

13 Fermentation- Big Picture C 6 H 12 O 6 2C 2 H 5 OH + 2CO 2 + H (56 KJ) Theoretical yield ~ 51.7% Actual yield ~ 40-48%

14 But it isn't so simple Glycolysis central pathway GLUCOSE INTERMEDIARIES PYRUVATE

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16 Malt Most important ingredient in beer making, from the standpoint of quality and functionality Barley malt is to beer as grapes are to wine Malted barley has a high amounts of enzymes for converting its starch supply into simple sugars Contains protein, which is needed for yeast Flavor

17 Malting Malting serves the purpose of: 1. converting insoluble starch to soluble starch (gelatinization) 2. reducing complex proteins 3. generating nutrients for yeast development 4. and the development of ENZYMES

18 Malting steps 1. Steeping 2. Germination 3. Kilning

19 Steeping Mixing the barley kernels with water to raise the moisture level and activate the metabolic processes of the dormant kernel. The water is drained, and the moist grains are turned several times during steeping to increase oxygen uptake Generally, the barley spends about 40 hours in tanks of fresh, clean water, with three intervals during which the water is allowed to drain. Draining is done to remove dissolved carbon dioxide and to reintroduce oxygen-rich water. Steeping is complete when the white tips of the rootlets emerge, which is known as chitting. At this point the grains will have swollen one and one-third times their original size.

20 Steeping

21 Germination Wet barley is germinated by maintaining it at a suitable temperature and humidity level until adequate modification has been achieved. Floor malting is an old process in which the chitted malt is spread on the floor to a height of 10 to 20 cm. GREEN MALT

22 Germinated barley

23 Kilning-drying Drying the green malt in the kiln Malts are kilned at different temperatures The temperature regime in the kiln determines the color of the malt and the amount of enzymes which survive for use in the mashing process.

24 Steeping vessel (42-48% moisture) Dryer Germination (5 days)

25 Overview of malting Storage Moisture Temperature 12-14% 12C Steeping Moisture 45% Germination Kiln drying Removal of rootlets Time Temperature Temperature Moisture 5 days 12-16C up to 85C 4%

26 Water The mineral content of brewing water has long been recognized as making an important contribution to the flavor of beer. The Ca, Mg, Na, K, Sulfites are most important constituents of water effecting brewing process and beer ph, Alkalinity and Hardness Breweries were located on sites with established, consistent water supplies having characteristic mineral compositions. This led to the emergence of regional beer characteristics in locations such as Dortmund, Pilsen, and Vienna.

27 Adjuncts Unmalted grains such as corn, rice, rye, oats, barley, and wheat they provide extract at a lower cost (a cheaper form of carbohydrate) beers with enhanced physical stability, superior chill-proof qualities, and greater brilliancy. contribute very little protein material which is advantageous in terms of colloidal stability. Flavor contribution rice - neutral aroma and taste corn - fuller flavor wheat - imparts a dryness to beer.

28 Yeast Responsible for converting fermentable sugars into alcohol and other byproducts. Saccharomyces cerevisie Saccharomyces uvarum There are two types of beer yeast 1. Ale yeast (the "top-fermenting" type) 2. Lager yeast (the "bottom-fermenting" type)

29 ALE Best used at temperatures ranging from 10 to 25ºC, yeasts rise to the surface during fermentation, creating a very thick, rich yeast head. That is why the term "topfermenting" is associated with ale yeasts. Produces a beer high in esters, which many regard as a distinctive character of ale beers. Saccharomyces cerevisiae Europe & Australia

30 Lager Yeast strains are best used at temperatures ranging from 7 to 15ºC. grow less rapidly than ale yeasts settle out to the bottom of the fermenter as fermentation nears completion This is why they are often referred to as "bottom" yeasts. Saccharomyces uvarum North America

31 Hops Impart color rich in tannins Flavor and aroma Provide proteins to yeast Aid in foam formation and stabilization Provides coagulation of proteins (to get rid of them) Inhibits most Gram + bacteria (Lactic acid)

32 General steps in beer making MASHING BREWING FERMENTATION STORAGE FINISHING AND PACKAGING

33 Malt milling Malted barley is crushed in the roller mill Resultant material is called the grist

34 Mashing Grounded malt + Water + adjuncts cereal MASH Mashing begins at ~ 38 C Temperature is gradually raised to 77 C Heating is done in steps with rest periods of ~30 min (Allows enzymes to work before they are heat inactivated)

35 Changes during mashing Extraction of readily soluble materials Gelatinization of starch (Only gelatinized starch is susceptible to enzymatic hydrolysis) Enzymatic break down of gelatinized starch to oligosaccharides, dextrins, maltose, glucose Proteins are also extracted and broken down to amino acids by proteolytic enzymes

36 MASHING VESSEL TUN WORT (liquid part) Mashing vessel is designed that way that after mashing, the liquid fraction high in yeast fermentabe sugars (WORT) can be separated from the grains

37 Brewing Wort Brew kettle or Wort Tun Hops Boiling for 2.5 h Drawing out the wort through a layer of settled hops Cooling

38 Purpose of brewing Concentration of wort ( more solids) Nearly sterilizes it Inactivates enzymes Precipitates remaining proteins (if not precipitated it would form beer turbidity) Caramelizes sugars slightly Extract flavor, preservative and tanninlike substances from hops

39 Fermentation Fermentable carbohydrates in the wort are converted by the yeast into alcohol, carbon dioxide, and numerous byproducts. The byproducts have a considerable effect on the taste, aroma, and other characteristic properties of the beer. Fermentation is dependent on the composition of the wort, the yeast, and fermentation conditions.

40 Ale vs. Lager fermentation ALE LAGER Ale yeast (top-fermenting) Ferments the wort in four to six days 15 to 20 degrees Celsius (59 to 68 deg. F). Fermentation with lager yeast (bottomfermenting) temperatures between 4 and 9 degrees C. (39.2 and 48.2 deg. F). It takes about eight days, Then the yeast settles to the very bottom.

41 Purpose of the fermentation Formation of ETOH (alcohol) Lowers the ph Produces dissolved CO 2 (0.3% by weight) Development of flavor components

42 Beer conditioning After fermentation beer is quickly cooled to 0 C Passed through a filter system to remove yeast and other suspended material Pumped into pressure storage tanks GREEN BEER

43 Storage of beer at 0 C LAGERING Further settling of finely suspended proteins, yeast and other remaining materials Development of esters and other flavor compounds (give beer improved body and mellow flavor)

44 Lagering-Chill haze Chill haze is phenomenon in which remaining proteins and tannins form a colloidal haze when beer is cooled to low temperature At higher temperatures this complex is soluble and it does not form haze This is allowed to happened during lagering to prevent it from occurring in finished product To remove this chill haze 1. Addition of earth of clay is applied during lagering to absorb this coloids 2. Proteolytic enzymes are added to break down the proteins

45 Lagering Adding CO 2 Carbon dioxide contributes to perceived "fullness" or "body" Enhances foaming potential Acts as a flavor enhancer Extends the shelf life of the product (purging out the oxygen). The closer the carbonating temperature is to 0ºC and the higher the pressure, the greater the carbon dioxide absorption. Brewer must know the maximum working pressure of the tanks, and when tanks are subject to overpressure.

46 Final finishing-filtering Filtration to remove traces of suspended material and give beer clear look Plate and Frame filter

47 Bottling The bottling of beer is one of the most complex aspects of brewery operations and the most labor intensive of the entire production process. The bottling of beer can be divided into the following steps: 1) flash pasteurization (71.5 to 74ºC and held at this temperature 15 to 30 seconds) (Not in USA) 2) bottle feeding 3) bottle rinsing, 4) bottle filling, 5) tunnel pasteurization (60ºC, several minutes) 6) bottle labeling, 7) case packing.

48 Beer bottling

49 Keg (Draft beer) Pasteurized or not Held under refrigeration temperature Filling carbonated pasteurized beer into sterile aluminum or stainless steel kegs of various sizes. Better taste?

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51 Beer spoilage microorganisms 1. Gram-positive Lactic acid bacteria Lactobacillus spp. Pediococcus spp. 2. Gram-negative: acetic acid bacteria Acetobacter spp Acetomonas spp. Zymomonas spp. Enterobacteriaceae.spp Pectinatus spp. 3. Molds Mucor, Penicillium, Aspergillus, Cladosporium, Geotrichum, and Rhizopus. 4. Wild yeasts

52 Types of beer Lager beer (North America, yeast on the bottom) Pilsner (light with medium flavor (North America)) Dortmunder (light lager with ~10% rice) Vienna (medium dark lager, mild hop taste) Munich ( lager, very dark in color, small amount of grapes used in brew to give slight sweet taste) Bock ( Lager, dark brown, strong hop taste) Ale Beer ( yeast remaining on the top) Guiness (dark color, mild hop taste, added grapes) Porter (dark brown and slightly reddish color, mild hop flavor)

53 Beer composition (4% alcohol) 90 % water 4.4g carbohydrate 6g protein 4mg of calcium 26mg of phosphorus 0.03mg of riboflavin (Vitamin B2) 0.2mg of niacin Trace of thiamin (vitamin B2) 0.2g of ash

54 Light beer Contains one half to one third less calories Less alcohol Prepared with mash lower in solids

55 Alcohol side effects dilation of blood vessels (which causes flushed skin) increased gastric secretion in the stomach mood swings unrestrained behavior inability to control motor functions as basic as walking blackouts sleep problems hangovers liver failure

56 Most famous beer drinker

57 QUESTIONS???????? HAVE A SAFE AND FUN SPRING BREAK